U.S. patent number 10,661,372 [Application Number 14/089,062] was granted by the patent office on 2020-05-26 for weld parameter interface.
This patent grant is currently assigned to Illinois Tool Works Inc.. The grantee listed for this patent is Illinois Tool Works Inc.. Invention is credited to Bruce Patrick Albrecht, Todd Earl Holverson, James F. Ulrich.
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United States Patent |
10,661,372 |
Ulrich , et al. |
May 26, 2020 |
Weld parameter interface
Abstract
A system and method for determining settings or parameters for a
welding-type power source are provided. By presenting an operator
with an interface that is positioned along the path of a weld cable
and configured to input weld characteristics, an operator is not
required to determine electrical parameters for setting a
welding-type power source output at the power source. The interface
is presented to the operator at a remote welding-type device, such
as a wire feeder, a weld robot, a torch, or the like. From the
operator-specified weld characteristics, the system and method
determine appropriate settings for the power source. In some
embodiments, the system and method may automatically set the power
source accordingly.
Inventors: |
Ulrich; James F. (Appleton,
WI), Albrecht; Bruce Patrick (Neenah, WI), Holverson;
Todd Earl (Appleton, WI) |
Applicant: |
Name |
City |
State |
Country |
Type |
Illinois Tool Works Inc. |
Glenview |
IL |
US |
|
|
Assignee: |
Illinois Tool Works Inc.
(Glenview, IL)
|
Family
ID: |
41360958 |
Appl.
No.: |
14/089,062 |
Filed: |
November 25, 2013 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20140144899 A1 |
May 29, 2014 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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12263920 |
Nov 3, 2008 |
8592722 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K
9/1087 (20130101); B23K 9/1062 (20130101); B23K
9/0953 (20130101) |
Current International
Class: |
B23K
9/095 (20060101); B23K 9/10 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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19602876 |
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Jul 1997 |
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DE |
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903195 |
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Mar 1999 |
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EP |
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0903195 |
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Mar 1999 |
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EP |
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987079 |
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Mar 2000 |
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EP |
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1158027 |
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Mar 1999 |
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JP |
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11170048 |
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Jun 1999 |
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JP |
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Other References
Rippey, Proceedings of NIST Workshop: Industry Needs in Welding
Research and Standards Development, National Institute of Standards
and Technology, Gaithersburg, MD, Apr. 1996. cited by applicant
.
International Search Report for application No. PCT/US2009/056328
dated Dec. 15, 2009. cited by applicant .
Written Opinion for application No. PCT/US2009/056328 dated Dec.
15, 2009. cited by applicant.
|
Primary Examiner: Evans; Geoffrey S
Attorney, Agent or Firm: McAndrews, Held & Malloy,
Ltd.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser.
No. 12/263,920, filed Nov. 3, 2008, now U.S. Pat. No. 8,592,722,
entitled "Weld Parameter Interface" in the name of James F. Ulrich
et al., which is incorporated herein by reference.
Claims
What is claimed is:
1. A welding-type user interface system comprising: a user
interface configured to display and receive a plurality of control
inputs indicative of a plurality of weld specifications, wherein
the plurality of weld specifications comprise one or more physical
attributes of a weld; a transmitter configured to transmit the
plurality of control input to a welding power source; and a
processor configured to convert, using a lookup table, the weld
specifications from the plurality of control inputs into electrical
parameters of a welding power source and a type of weld wire, and
to control an output welding power of the welding power source
based at least in part on the electrical parameters.
2. The welding-type user interface system of claim 1 wherein the
processing unit is further programmed to determine the electrical
parameters using only the weld specifications as inputs.
3. The welding-type user interface system of claim 1 wherein the
transmitting unit is further configured to transmit the plurality
of control inputs via at least one of a weld cable, a
communications cable, and an antenna.
4. The welding user interface system of 1 wherein the processing is
programmged to store a set of default welding power source settings
and automatically adjust one or more of the default welding power
source settings when a user adjusts one control input of the
plurality of control inputs.
5. The welding user interface system of claim 1 wherein the welding
user is configured to display at least one of an image of a
selected weld and the electrical parameters to a user for approval,
and wherein the weld specifications are determined from a computer
aided design (CAD) file downloaded from one of a computer network
and a handheld computing device.
6. The welding user interface system of claim 1, comprising a power
receiver configured to receive electrical power from the welding
power source via a weld cable, and to power the user interface
using the received electrical power.
7. The welding user interface system of claim 1, comprising a
handheld device that comprises the user interface and the
transmitter.
8. The welding user interface system of claim 1, wherein the
transmitter is further configured to transmit the plurality of
control inputs wirelessly.
9. A method for setting welding parameters comprising: receiving,
via a user interface, a plurality of control inputs indicative of a
plurality of weld characteristics, wherein the plurality of weld
characteristics comprise one or more physical attributes of a weld;
determining, using a first lookup table, a set of power source
parameters based on the received plurality of control inputs;
determining, using the first lookup table or a second look-up
table, a type of weld wire based on the received plurality of
control inputs; outputting an indication of the type of weld wire
via the user interface; transmitting the set of power source
parameters to a power source output controller; and conditioning
welding-type power based on the set of power source parameters.
10. The method of claim 9 wherein the welding device is at least
one of a wire-feeder and a welder-type gun.
11. The method of claim 9 further comprising storing the set of
power source parameters as a set of default parameters for future
use.
12. The method of claim 9 further comprising displaying the set of
power source parameters for approval prior to transmitting the set
of power source parameters to the power source output
controller.
13. The method of claim 9 further comprising determining the set of
power source parameters from only the particular weld
characteristics.
14. The method of claim 9, comprising powering the user interface
using electrical power received from a welding power source via a
weld cable.
15. The method of claim 9, wherein the user interface is connected
to a handheld device.
16. The method of claim 15, comprising transmitting the plurality
of control inputs from the handheld device.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to welding, and, more
particularly, to a weld parameter interface system and method which
calculate electrical requirements or other settings for a welding
process from weld characteristics, such as a material to be welded,
joint configuration, weld dimensions or other parameters. By
allowing users to describe a weld to be performed rather than
electrical requirements, the system and method of the present
invention can simplify and/or automate the electrical calibration
of a power source for a particular welding procedure.
As new advances in the welding arts develop, the level of user
knowledge required to operate advanced welders has correspondingly
increased. In other words, the more features and capabilities
incorporated into a welder, the more an operator must learn or
remember in order to utilize the new features and capabilities.
Many present welding systems and power sources prompt a user to
specify such settings as weld voltage, current, signal frequencies,
and electrical operation modes like constant current (CC) and
constant voltage (CV). Some systems even prompt a user to define
particular welding power waveforms, in which case an operator must
enter in such specific details as rise times, fall times, pulse
widths, and the like.
In contrast, many weld operators are prone to understand welding
processes in terms of the physical characteristics of the weld
itself. It stands to reason that, since an operator is primarily
concerned with making a weld, the operator will think of the
welding procedure in terms of the weld itself and not in terms of
power settings. That is, most operators will find it far easier to
describe a welding process in terms of the workpiece materials,
thicknesses, and weld joint types, rather than voltages, currents,
and waveforms.
Requiring operators to learn electrical parameters and translate
their weld description into electrical settings can diminish, to
some extent, the advantages presented by technically advanced
welding systems. When an operator must spend significant amounts of
time in being constantly re-trained in new electrical settings or
when an operator takes longer to adjust a new power source, the
overall efficiency of a manufacturing process is reduced.
Additionally, when experienced operators must be re-trained to
think of weld settings in terms of electrical parameters, years of
operator experience may be put to waste.
Some present systems have adjustment knobs or other interfaces
located on the power source, so that users can adjust various power
source settings in the field. Other systems utilize hand-held
computers which are plugged directly into the power source for
adjustment thereof These procedures may be inconvenient for an
operator who is welding remotely from the power source. They use
additional parts and connections, or require the operator to set
down the torch, walk back to the power source to adjust settings,
then walk back to the weld area. When an operator is located inside
a ship hull, for example, walking back to a power source located
outside the ship hull can present a very real inconvenience.
Additionally, though these systems sometimes provide for some
quasi-physical input settings, such as wire feed speed or material
descriptions, such systems typically contemplate that operators
will still be directly adjusting at least some electrical
parameters.
It would therefore be desirable to have a system and method capable
of translating an operator's weld-characteristic understanding of a
welding procedure into particular optimal settings for a power
source, such as electrical settings. It would further be desirable
for such a system and method to include a simple, intuitive user
interface which is integrated into a remote device, for reduced
parts and complexity and ease of power source adjustment.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides a system and method for adjusting
power source parameters which overcomes the aforementioned
drawbacks. Embodiments of the present invention provide for
adjustment/control of power source settings based on descriptions
of a weld procedure to be performed. In addition, embodiments of
the present invention include interfaces which are integrated into
remote devices and present simple weld-term options, for increased
simplicity.
Therefore, according to one aspect of the invention, a welding-type
system includes a power source constructed to deliver a conditioned
welding power on a weld cable, a peripheral device connected
remotely from the power source along the path of the weld cable,
and a user interface connected to the peripheral device. The weld
cable defines a path from the power source to a welding electrode.
Further, the user interface is adapted to input at least one weld
attribute and communicate the at least one weld attribute to a
processing unit. The processing unit determines a set of power
source parameters from the at least one weld attribute and causes
the power source to condition the welding power in accordance with
the set of power source parameters.
In accordance with a further aspect of the invention, a
welding-type user interface system includes a display comprising a
set of control inputs configured to communicate weld
specifications, a power receiver to receive electrical power from a
weld cable to at least power the display, a processing unit
programmed to convert the weld specifications from the set of
control inputs into welding-type power source settings, and a
transmitting unit configured to transmit the settings to a
welding-type power source. The settings are used to adjust
welding-type output power of the welding-type power source.
Further, the weld cable couples the welding-type power source to a
welding-type torch.
According to another aspect of the present invention, a method for
setting welding parameters includes presenting a number of weld
characteristic options on a user interface, wherein the user
interface is connected to a welding-system device that is remote
from a welding-type power conditioner, determining a set of
electrical power source parameters based on user selection of
particular weld characteristics, transmitting the set of power
source parameters to a power source output controller, and
conditioning welding-type power based on the set of power source
parameters. The weld characteristics comprise physical attributes
of a weld.
Various other features and advantages of the present invention will
be made apparent from the following detailed description and the
drawings.
DRAWINGS
The drawings illustrate one preferred embodiment presently
contemplated for carrying out the invention.
In the drawings:
FIG. 1 is a perspective view of a welding system, in accordance
with one embodiment of the present invention.
FIG. 2 is a diagram of an exemplary graphical user interface for
the welding system of FIG. 1.
FIG. 3 is a diagram of an alternative user interface for the
welding system of FIG. 1.
FIG. 4 is a schematic block diagram of the connectivity between a
welding-type power source and a user interface system of a remote
device in accordance with one embodiment of the invention.
FIG. 5 is a schematic block diagram of the connectivity between a
welding-type power source and a user interface system of a remote
device in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
The present invention finds applicability with all welding or
weld-related systems including, but not limited to, systems
utilizing power sources which are located remotely from the
operator and the workpiece/weld. Therefore, embodiments of the
invention will be discussed below with respect to systems which
utilize wire feeders, weld robots, sophisticated torches, other
user-adapted accessories, and the like. However, it is to be
understood that the features and advantages described for a given
welding-type system or configuration are equally applicable to
other welding-type systems. For example, discussion of the present
invention with respect to remote wire feeders shall be understood
to extend to other remote devices equivalently.
Referring to FIG. 1, a welding-type system 10 is shown
incorporating the present invention. System 10 includes at least
one power source 12, which can be an AC or a DC welding power
supply operable in either a constant current (CC) or a constant
voltage (CV) mode. The power source 12 has a work cable 14 and
clamp 16 designed to connect power source 12 to a workpiece 18 for
welding. A power cable 19 carries conditioned welding-type power
from the power source 12 to a wire feeder 21. A welding cable 22
carries conditioned welding-type power from the wire feeder 21 to a
welding-type electrode 20 extending from a gun or torch 24. As
shown, the power source 12 can be connected, via the cables 19 and
22, to remote or peripheral devices such as the wire feeder 21 and
the gun or torch 24. It is appreciated, however, that the present
invention finds applicability in systems having remote or
peripheral devices other than, or in addition to, wire feeder 21
and gun or torch 24. Preferably, wire feeder 21 is configured to
drive consumable weld wire to a weld according to various operating
modes. As shown, wire feeder 21 is a separate component from power
source 12, though it is appreciated that wire feeder 21, or other
remote devices, may be in a permanent configuration with power
source 12. Wire feeder 21 includes a welding torch or gun 24 and a
voltage sensing lead with clip 26 configured to provide voltage
feedback from the weld to the wire feeder 21. A shielding gas
cylinder 28 is also connected to the wire feeder 21, and includes a
valve that is selectively activated to provide shielding gas for
the welding process.
When welding torch 24 is triggered, welding wire is fed from wire
feeder 21 toward the workpiece 18. As the wire approaches the
workpiece 18, an electrical arc is established which generates
current and voltage, causing the welding wire to be heated and melt
to the workpiece 18, whereupon the welding wire fuses and cools
with the workpiece 18. Because the electrical energy supplied at
the weld is greater than that required to melt the welding wire,
most of the remaining energy is in the form of heat which is
transferred to the surface of the workpiece 18 resulting in the
workpiece 18 also melting and improving bonding between the melted
welding wire and the workpiece 18. As welding torch 24 is
translated across workpiece 18, melted welding wire is continuously
transferred to the workpiece 18.
Wire feeder 21 also has a user interface 30 integrated therewith,
for selecting power source parameters. Interface 30 is shown as a
graphical user interface (GUI), though it is appreciated that a
physical interface comprising knobs and the like may equivalently
be used. In embodiments where interface 30 is a GUI, interactivity
with the GUI may be via a keyboard, keypad, touch screen, voice
commands, knobs or dials, and/or a communication port for
connectivity with other devices like laptop computers or hand-held
devices (not shown). Similarly, torch 24 is shown having a physical
interface 32 integrated thereon. Interfaces 30 and 32 may be used
alternatively, or in combination, to allow an operator to specify
characteristics of an impending weld. These weld characteristics
may be translated into power characteristics and used to adjust
power settings of power source 12. As such, an operator is saved
from the inconvenience of having to return to power source 12 each
time a change in the power source output is sought. User selections
or inputs received by the interfaces 30, 32 may also cause changes
in the operating mode of wire feeder 21.
Referring now to FIG. 2, a more detailed view of a GUI is shown.
GUI 40 may be presented on a display of a remote wire feeder, a
torch, or other remote device. GUI 40 allows an operator to specify
physical characteristics of a weld which the operator will be
making, including welding materials, weld joint configuration
parameters, and weld bead parameters. Based on the selected weld
characteristics, a processor (e.g., processor 128, 138 of FIGS. 4
and 5, respectively) determines the electrical parameters which
will be used to set the power source to achieve optimal weld
conditions. The processor running the GUI 40 may automatically set
the electrical parameters in the power source 12. Alternatively,
the GUI 40 may simply display the electrical parameters to an
operator for approval or manual setting.
GUI 40 is shown having a weld type or weld joint selection menu 42.
An operator may specify that the impending weld is to have a "BUTT"
joint 46, a "CORNER" joint 48, an "EDGE" joint 50, a "LAP" joint
52, a "TEE" joint 54, or other weld joint type. As shown, these
selections are made via radio buttons, though it is appreciated
that other conventions such as check boxes, drop-down boxes, or
tabs may be used equivalently. When a user selects a weld type
option, such as a BUTT joint 46, weld depiction window 44 will
display a generalized view of the type of weld/joint which has been
selected. As shown, a butt weld 56 is displayed in depiction window
44.
In addition, an operator may specify the type of workpiece
material(s) via drop down menu 58. Thus, GUI 40 may be programmed
to present a list of material types, such as various alloys,
grades, and types of metals. In certain embodiments, GUI 40 may be
pre-programmed to present only common or user-preferred material
types. GUI 40 may be further programmed to automatically set
default selections for each weld type. As an example, FIG. 2
illustrates the selection of a 309 Stainless Steel workpiece
material. Similarly, GUI 40 allows a user to select a thickness of
the workpiece(s). Preferably, GUI 40 will display, in drop down
menu 60, a number of preferred or common material thickness options
for the material type selected in menu 58. When an operator selects
a workpiece material and thickness, the graphical display 56 of the
weld can be automatically updated to reflect the chosen
characteristics.
Text boxes 60-68 allow an operator to describe the weld itself, in
terms of weld attributes or characteristics. These weld attributes
can include, for example, the desired fillet size 62, penetration
depth 64, penetration profile 66, and bead width 68. Thus, an
operator can manually enter the desired characteristics, rather
than selecting them from menus. It is appreciated, however, that
other GUI conventions, such as menus and checkboxes may be used for
inputting weld characteristics, or a click-and-drag type scalable
control could be included in the GUI for increasing/decreasing a
parameter value, such as the bead width. The weld attributes can
also be shown in the weld depiction window 44, and the display can
be modified as the weld attribute values are adjusted. Typically,
welding operators will understand these characteristics better than
the associated electrical parameters which will produce them.
Depending upon the welding system type into which GUI 40 is
integrated, GUI 40 may also present menus or text boxes 70, 80, and
82 for operators to specify wire types, wire feed speeds, and gas
types, respectively.
GUI 40 also contains a number of command buttons 72-78. When an
operator has specified the desired weld characteristics (or
accepted the default characteristics), the operator may activate
the "Calculate Electrical Parameters" button 72. The GUI will then
determine and display the optimal electrical parameters by which to
set the power source. These parameters may include a power source
voltage setting 84, a power source current setting 86, a power
source frequency 88, and an operation mode 90 (such as constant
current CC, constant voltage CV, or pulse). Pulse parameters, such
as a pulse width, rise time, and fall time could also be
calculated. In applications where a wire feeder 21 is used, a wire
feed speed may also be calculated (not shown). GUI 40 may also
allow an operator to alter previously-selected weld characteristics
and have the GUI re-determine electrical parameters 84-90, by
activating the "Refresh" button 74.
In addition to being used to determine the optimal electrical
parameters by which to set the power source, the desired weld
characteristics input by a user can also be used in determining a
proper weld wire type. That is, the input of the desired weld
characteristics described above can be used for determining a
composition, size, and/or brand of weld wire that is suitable for
use with a peripheral wire feeder 21 (shown in FIG. 1) for the
described welding operation. A "Determine Weld Wire Type" button
91, FIG. 2, is included on GUI 40 and, when an operator has
specified the desired weld characteristics (or accepted the default
characteristics), the operator may activate the "Determine Weld
Wire Type" button 91. The GUI 40 will then determine and display
the optimal weld wire type for use in the wire feeder and display
this information at weld wire display 93.
An operator may also choose to import preset weld characteristics
and/or electrical parameters by activating the "Import" button 76.
Import button 76 may allow a user to retrieve previously saved sets
of characteristics from local memory storage or to input weld
characteristic from an outside data source. For example, weld
characteristics may be uploaded directly from a CAD file or other
architectural or engineering specification, a laptop computer, a
hand-held device, or computer network. In other words, the user
interface system may download or receive data from a schematic
specification file from a computing-type device and use such data
to determine the weld characteristics. The "Store Settings" button
78 may be used to create stored sets of characteristics from the
current settings displayed GUI 40. These sets of weld
characteristics can then be retrieved for quick parameter setting
via the "Import" button 76.
Referring now to FIG. 3, an alternative embodiment of a weld
characteristic interface is shown. Interface 92 is less graphical
than the interface of FIG. 2, and may be integrated into one or
more remote devices such as weld torch handle 94. Having interface
92 located on, or coupled to, a remote device may increase work
efficiencies. That is, since an operator will no longer need to
move to a welding-type power conditioner to adjust power
conditioning power settings, the length of work flow interruptions
may be minimized. In this less graphical embodiment, interface 92
includes a number of physical controls, such as knobs, buttons and
dials 96-102 which present weld characteristic options to an
operator. It will be appreciated that the number, size, and
arrangement of controls 96-106 may vary and may depend upon the
type of torch handle or other remote device into which interface 92
is integrated. Interface 92 may also have a cover (not shown) to
enclose the controls 96-106 during a welding operation, to prevent
inadvertent changes to weld characteristic settings.
Interface 92 has a weld/joint type selector knob 98, by which an
operator may designate the impending weld as a butt joint "B," a
corner joint "C," an edge joint "E," a lap joint "L," or a tee
joint "T." In various embodiments, knob 98 may be a hand-turnable
knob or a screw driver-turnable knob. In a similar manner, an
operator may also specify the dimensions of the weld by turning
knob 96. Weld dimension knob 96 may specify the weld fillet size,
penetration depth, bead width, or other similar characteristics.
Additional knobs (not shown) may also be present on interface 92 to
permit operators to specify more or all of these dimensions. The
type of workpiece material may be selected in a number of ways. As
shown, interface 92 includes a small LCD display 104 and a scroll
button 100. By depressing button 100, display 104 will scroll
through a list of workpiece material types, until the desired
material type is shown. Alternatively, it is appreciated that other
controls, such as switches, could be used to select workpiece
material types.
Interface 92 may set electrical parameters in the power source
connected to the remote device 94 in a number of ways. For example,
interface 92 may register changes to weld characteristics only
prior to commencement of a weld operation, and may therefore allow
an operator to only manually adjust power source parameters during
a weld operation. In addition, interface 92 may only set electrical
parameters after a user has specified all the desired weld
characteristics. In this manner, interface 92 may have a "Set Power
Source" button 106. Alternatively, interface 92 may simply adjust
power source parameters in real time as the weld characteristics
are changed.
Referring now to FIG. 4, a schematic block diagram conceptually
illustrating the connectivity between a power source and a user
interface system of a peripheral device is shown. Power source 110
provides conditioned power via a weld cable 112, which in the
present embodiment is connected to wire feeder 114 and torch 116.
Generally, power source 110 includes a primary transformer 118 to
condition welding-type power, a power output controller 120 to
control the output of transformer 118, and a receiver 122 to
receive operator-selected data and communicate the data to
controller 120. In some embodiments, receiver 122 may receive weld
characteristics from a user interface system such as interface
system 124 of wire feeder 114 or interface system 126 of torch 116.
In such embodiments, receiver 122 will communicate the weld
characteristics to a processing unit 128 of power source 110 for
the determination of power source electrical parameters. Receiver
122 may be configured to receive input data via weld cable 112 or
data cable 130, or it may be configured to allow for wireless
communication via antenna 131.
Processing unit 128, or an associated memory component (not shown),
may have stored thereon a lookup table or a set of conditions and
constraints by which electrical parameters are determined That is,
a lookup table or database of electrical parameters may be parsed
according to the user-selected weld characteristics. Such a lookup
table may be determined and stored in processing unit 128 by the
manufacturer of power source 110. Alternatively, the electrical
parameter values in the lookup table may be saved or altered by an
operator, to personalize the electrical parameter determination. In
this regard, more than one lookup table may be stored on processing
unit 128, such that multiple operators may store their own
individualized electrical parameter profiles.
For example, an operator at the remote device 114 could enter an
operator ID instructing the processing unit 128 which profile to
use. Then, the operator could specify a given weld joint type,
material type, material thickness, weld profile, etc. Using these
characteristics, the processing unit 128 will parse the lookup
table and find a set of electrical parameters which have been
stored as the optimal parameters to achieve the specified weld.
Stored electrical parameters may include particular weld voltage,
weld current, frequency, operation mode settings, and the like.
These settings may then be communicated to the controller 120 for
adjustment of the power source output. Accordingly, some degree of
operator guesswork can be removed from power source electrical
settings.
Processing unit 128 may also be configured to begin with pre-set
default electrical parameters, if no weld characteristics are
specified by a user. When an operator alters a weld characteristic,
processing unit 128 may then determine whether one or more
electrical settings of the power source 110 need to be
adjusted.
Positioned along the path of weld cable 112, user interface system
124, seen as part of the wire feeder 114 (i.e., a peripheral
welding-type device), allows for the input and communication of
weld characteristics. As shown in the present embodiment, user
interface system 124 includes a transmitter 132, a display 134, and
power receiver 136. In the present embodiment, the power receiver
136 receives power via the weld cable 112 to at least power the
display 134. It is contemplated that the interface system 124 may
also include a processor 138 and a port or data receiver 140. The
port or data receiver 140 can be used to download weld information
from a remote computing-type device. As such, it is contemplated
that port or data receiver 140 could take on the form of a plug-in
receptacle if a data link (not shown) is used for downloading or an
antenna if downloading is to occur wirelessly. The transmitter 132
is configured to send operator-selected weld characteristics from
interface 124 to power source 110. Alternatively, weld
characteristics may be communicated from interface system 126 of
torch 116 to transmitter 132 via a separate data cable 142.
Transmitter 132 may be configured to transmit the
operator-specified weld characteristics wirelessly, via weld cable
112, or via a separate data cable 130.
The operator-specified weld characteristics are preferably
communicated to the receiver 122 of power source 110 via the weld
cable 112. Such communication may, for example, take the form of a
modulation and/or encoding of a power signal on the weld cable 112,
or be performed by a separate digital or analog serial protocol.
Exemplary methods and systems for providing communications via a
weld cable are described in U.S. Patent Application Publication
2006/0086706, published Apr. 27, 2006, U.S. Pat. No. 7,180,029,
issued Feb. 20, 2007, and U.S. Patent Application Publication
2007/0080154, published Apr. 12, 2007, all of which are hereby
incorporated by reference for their disclosure of such methods.
However, although communications can be provided through the weld
cable 112, it may be desirable in other embodiments to include
separate data cable 130 to communicate weld characteristics to
power source 110. For example, bandwidth, impedance, or noise
constraints may make a separate cable more desirable. Or, in
instances where embodiments of the invention are used as retrofits
to existing welding-type systems, a separate data cable 130 may be
easier to implement. In such embodiments, data cable 130, rather
than weld cable 112, may be used to power at least display 134 of
power interface system 124. Additionally, and as discussed above,
the interface system (e.g., interface system 124 and 126) of the
accompanying remote device (e.g., wire feeder 114 and gun or torch
116, respectively) may include an antenna for wireless
communication.
As mentioned above, in an alternative embodiment, user interface
system 124 may also include an on-board processing unit 138. In
such an embodiment, the electrical parameter determinations may be
conducted by the on-board processing unit 138 of the user interface
system 124 connected to, or incorporated into, wire feeder 114 (or
another remote device such as torch 116). Accordingly,
communication of the electrical parameters may be accomplished
wirelessly, via the weld cable 112, and/or via the data cable 130,
obviating a need for a processing unit 128 in the power source
110.
On-board processing unit 138 can also control additional weld
settings, such as wire feed speed. As shown, wire feeder 114 has a
set of rollers 144 for advancing a consumable weld wire 146 to a
gun or torch 116. As such, based on an operator specified weld
joint type, material type, material thickness, weld profile, etc.,
the on-board processing unit 138 can determine an optimal wire feed
speed and communicate this value to wire feeder 114. It is also
envisioned that on-board processing unit 138 could control travel
speed (if the welding process is automated), by determining an
optimal welding speed and relaying this value to a fixed automation
system or robot, such as a computer-numerical control (CNC) robot
welder (not shown).
It is contemplated that the user interface system may be a
component affixed to or incorporated into a peripheral device such
as wire feeder 114 and/or torch 116. However, it is also
contemplated that user interface system may be comprised of
multiple components (e.g., a separate transmitter 132, display 134,
power receiver 136, processor 138, and port or data receiver 140)
that are each affixed and/or incorporated into a peripheral device
(e.g., wire feeder 114 and torch 116) along the weld cable 112
path. In either case, the interface system allows for a power
source to be set or adjusted in an efficient and intuitive
manner.
As discussed above, it is also contemplated that an interface may
be coupled to welding-type devices other than a wire feed 114 or
torch 116. For example, it is envisioned that user interface 132
could be implemented as part of a welding robot (not shown) along a
weld cable path and in communication with power source 110. Here,
the receiver 122 in power source 110 can be a wireless
communications device capable of connecting the power source to a
wireless communications network, a connector such as an Ethernet
connector for connecting the power source to a local area or wide
area network, or a communications device capable of TCP/IP
communications with a computer through an internet link. In any of
these cases, data entered into an interface system of the robot is
transmitted to the receiver 122 in power source 110, and to the
wire feeder 114. Based on operator input of weld characteristics or
attributes, power source electrical parameters may be determined at
the robot and transmitted to the power source 110, or may be
determined at the processing unit 128 in power source. As such,
work efficiencies can be maximized.
Furthermore, although the system is described above for use with a
metal inert gas (MIG/GMAW) or pulsed MIG system, it will be
apparent that the invention described herein also has application
to other types of welding applications, including tungsten inert
gas (TIG/GTAW) shielded metal arc welding (SMAW or stick welding),
flux cored arc welding (FCAW), and other applications.
Referring to FIG. 5, in an alternate embodiment to that shown in
FIG. 4, an operator interface may be implemented as an interface
154 on separate handheld remote 156 wirelessly connected to wire
feeder 114. Handheld remote 156 includes a transmitter 158 therein
to send operator-selected weld characteristics from interface 154
to wire feeder 114 via wireless communication signals 160. Wireless
communication signals 160 are received by processor 162 via antenna
164 and the weld characteristics contained in the wireless
communication signals 160 are processed by processing unit 162 to
determine power source electrical parameters. Interface 154
wirelessly connected 160 to wire feeder 114 may be implemented as a
stand-alone interface or be used in conjunction with interface 146
on torch 116. Additionally, it is also envisioned that interface
154 could be implemented as part of a networked computer in
wireless communication with wire feeder 114 rather than being in
the form of handheld remote 156.
Accordingly, an interface remote from a power source has been
described in a number of embodiments for determining and/or
automatically setting electrical power source parameters from
operator-supplied weld characteristics.
In accordance with one embodiment, a welding-type system includes a
power source constructed to deliver a conditioned welding power on
a weld cable, a peripheral device connected remotely from the power
source along the path of the weld cable, and a user interface
connected to the peripheral device. The weld cable defines a path
from the power source to a welding electrode. Further, the user
interface is adapted to input at least one weld attribute and
communicate the at least one weld attribute to a processing unit.
The processing unit determines a set of power source parameters
from the at least one weld attribute and causes the power source to
condition the welding power in accordance with the set of power
source parameters.
According to another embodiment, a welding-type user interface
system includes a display comprising a set of control inputs
configured to communicate weld specifications, a power receiver to
receive electrical power from a weld cable to at least power the
display, a processing unit programmed to convert the weld
specifications from the set of control inputs into welding-type
power source settings, and a transmitting unit configured to
transmit the settings to the welding-type power source. The
settings are used to adjust welding-type output power of the
welding-type power source. Further, the weld cable couples the
welding-type power source to a welding-type torch.
In accordance with a further embodiment, a method for setting
welding parameters includes presenting a number of weld
characteristic options on a user interface, wherein the user
interface is connected to a welding-system device that is remote
from a welding-type power conditioner, determining a set of
electrical power source parameters based on user selection of
particular weld characteristics, transmitting the set of power
source parameters to a power source output controller, and
conditioning welding-type power based on the set of power source
parameters. The weld characteristics comprise physical attributes
of a weld.
The present invention has been described in terms of the preferred
embodiment, and it is recognized that equivalents, alternatives,
and modifications, aside from those expressly stated, are possible
and within the scope of the appending claims.
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